Overhead support structure for intelligent locomotion for objects and equipment along two or more axes of movement

ABSTRACT

A support structure provides two or more axes of intelligent locomotion for a movable object on the support structure. The support structure can include a track system made up of a plurality of identically configured track modules that are connected end-to-end. Each track module can include an elongated body defining a longitudinal axis and having two ends. Each end can include at least one beveled edge and at least one track surface extending longitudinally along the elongated body. The track modules can be connected to a power source and include electrical contacts that provide electricity to movable objects that travel along the track system.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation under 35 U.S.C. § 120 of U.S.application Ser. No. 15/674,119, filed Aug. 10, 2017, the contents ofwhich is incorporated by reference herein in its entirety.

TECHNICAL FIELD

The disclosed technologies relate generally to overhead supportstructures for objects and equipment, and more particularly to a tracksystem that allows for intelligent locomotion of objects and equipmentalong two or more axes of movement.

BACKGROUND

Commercial and industrial spaces often have equipment mounted from theceiling to service spaces below the equipment. In many cases, theequipment is installed above the space in one location where theyservice the entire space.

Conventional lighting systems for commercial spaces often feature one ormore light fixtures that are installed in a ceiling or overhead supportstructure. The lighting fixtures can be arranged in a variety ofconfigurations designed to provide the appropriate amount of light, andthe appropriate distribution of that light, throughout the space. Oncethe lighting arrangement is installed, the options for changing theamount of light and distribution of light in the space are fairlylimited. This can create challenges, particularly in multi-use spacesthat are used for different purposes or events, where each purpose orevent has its own unique lighting needs, and where the space must bereconfigured from one purpose or event to another purpose or event on afrequent basis.

Conventional track lights allow the user to manually change the positionof an otherwise stationary light fixture, but only within the limitedconfines of the track, which is typically linear and limited in length.Some track lights also allow the user to pivot the light fixture inplace, so as to change the direction of illumination from that locationon the track. Manual adjustment of individual light fixtures in a largespace containing several light fixtures can be labor intensive andrequire a significant amount of downtime where the space cannot be used.For this reason, manually adjustable track lights are not preferred forspaces that are frequently reconfigured for different purposes.

SUMMARY

Support structures described by way of example herein resolve some orall of the drawbacks of conventional overhead mounting arrangements byallowing equipment or other overhead objects to be moved and rearrangedalong two or more axes of movement. In one example, a track system isconfigured for installation over a space. One or more autonomousself-propelled units, each carrying a piece of equipment or object,travel on the track system. Each self-propelled unit can move alongmultiple axes on the track system to reposition and reorient the pieceof equipment or object that it carries.

In a first example, a track module includes an elongated body defining alongitudinal axis and having two ends. Each end includes at least onebeveled edge. The track module also includes at least one track surfaceextending longitudinally along the elongated body. The at least onetrack surface includes a plurality of protuberances arranged in rows andin columns. The rows are parallel to the longitudinal axis of theelongated body, and the columns are perpendicular to the longitudinalaxis of the elongated body. The track module is configured forconnection with another track module to construct a track system thatprovides two axes of intelligent locomotion for a self-propelled unit onthe track system.

In a second example, a track system includes a plurality of trackmodules connected end-to-end. Each track module includes an elongatedbody defining a longitudinal axis and having two ends. Each end includesat least one beveled edge. The track modules also includes at least onetrack surface extending longitudinally along the elongated body. The atleast one track surface includes a plurality of protuberances arrangedin rows and in columns. The rows are parallel to the longitudinal axisof the elongated body, and the columns are perpendicular to thelongitudinal axis of the elongated body. The track system provides twoaxes of intelligent locomotion for a self-propelled unit on the tracksystem.

Additional objects, advantages and novel features of the examples willbe set forth in part in the description which follows, and in part willbecome apparent to those skilled in the art upon examination of thefollowing and the accompanying drawings or may be learned by productionor operation of the examples. The objects and advantages of the presentsubject matter may be realized and attained by means of themethodologies, instrumentalities and combinations particularly pointedout in the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawing figures depict one or more implementations by way of exampleonly, not by way of limitations. In the figures, like reference numeralscan refer to the same or similar elements.

FIG. 1 is a perspective view of a self-propelled unit;

FIG. 2 is a side view of the self-propelled unit of FIG. 1;

FIG. 3 is a cross section view of the self-propelled unit of FIG. 2,taken through line 3-3 in FIG. 2;

FIG. 4 is a cross section view of the self-propelled unit of FIG. 2,taken through line 4-4 in FIG. 2;

FIG. 5 is a bottom view of the self-propelled unit of FIG. 1;

FIG. 6 is a functional block diagram of a control system andself-propelled unit;

FIG. 7 is a high-level flow diagram of a control process;

FIG. 8 is a flow diagram of a more detailed example of a controlprocess;

FIG. 9 is a perspective view of a grid type support structure;

FIG. 10 is a perspective view of two components of the support structureof FIG. 9;

FIG. 11 is a perspective view of two components of the support structureof FIG. 9, shown with a self-propelled unit positioned at a firstlocation in the support structure;

FIG. 12 is a bottom view of a component of the support structure of FIG.9, shown with a self-propelled unit positioned at a second location inthe support structure;

FIG. 13 is a truncated perspective view illustrating details ofcomponents of a self-propelled unit and a section of a supportstructure;

FIG. 14 is an enlarged elevation view of components of a self-propelledunit in and a section of a support structure;

FIG. 15 is a side elevation view of a component of the support structureof FIG. 9, shown with a self-propelled unit positioned at a thirdlocation in the support structure;

FIG. 16 is a cross section view of the component of the supportstructure and self-propelled unit of FIG. 15, taken at line 16-16 inFIG. 15;

FIG. 17 is an end view of a component of the support structure of FIG. 9and a self-propelled unit shown inside the component;

FIG. 18 is a perspective view of two components of an alternate exampleof a support structure;

FIG. 19 is a perspective view of two track segments of the supportstructure of FIG. 9;

FIG. 20 is a plan view of a first track surface arrangement utilizingmultiple track segments of the types shown in FIG. 19; and

FIG. 21 is a plan view of a second track surface arrangement utilizingmultiple track segments of the types shown in FIG. 19.

DETAILED DESCRIPTION

In the following detailed description, numerous specific details are setforth by way of examples in order to provide a thorough understanding ofthe relevant teachings. However, it should be apparent to those skilledin the art that the present teachings may be practiced without suchdetails. In other instances, well known methods, procedures, components,and/or circuitry have been described at a relatively high-level, withoutdetail, in order to avoid unnecessarily obscuring aspects of the presentteachings.

Apparatuses and systems described below and shown in the drawings, byway of examples, can include various types of self-propelled units thatare configured to support objects on a support structure above a space.Such self-propelled units are operable to travel on the supportstructure to move objects to desired locations on the support structurebased on an instruction from a user, or an input received from a systemcontroller.

Various types of support structures can also be utilized, including butnot limited to a two dimensional grid layout comprising support elementsarranged in evenly-spaced rows and columns. As an alternative, thesupport structure can comprise support elements arranged in an irregulararrangement with evenly-spaced or unevenly-spaced rows and columns.Irregular arrangements can be designed with a symmetrical orasymmetrical layout of support elements.

Support elements can include various structures suitable for navigatingand conveying a unit along a desired route, including but not limited tovarious types of tracks, rails, beams, channels, tubes and otherconveyance means. These tracks, rails, beams, channels, tubes and otherconveyance means can be used alone or in any combination to form asupport structure that permits movement along two or more axes ofmovement. For example, support structures can be in the form of asubstantially horizontal support system that allows the self-propelledunit to travel along only two axes of movement (a “two-dimensionalsupport structure”). Alternatively, support structures can includesloped elements or members that create vertically ascending anddescending sections in the support structure that allow for three axesof movement (a “three-dimensional support structure”). Self-propelledunits can also include on-board mechanisms and assemblies for verticallyraising and lowering equipment or objects relative to the supportstructure, such as pendant lights that are suspended from self-propelledunits with aircraft cable or other means.

Self-propelled units can move on support structures in two dimensionsexclusively by translation. That is, each self-propelled unit maintainsthe same orientation relative to the support structure as its directionof movement changes. In this arrangement, the self-propelled unit neverrotates when changing direction at an intersection.

Apparatuses and systems can be used to support, carry and repositionmany types of objects on a support structure, with applicationsincluding but not limited to lighting, signage, displays, HVAC,decorations, Wi-Fi, location service, anchors, disability services,audio components, store guidance, immersive entertainment lighting, UVcleaning, custodial, power distribution, stand-alone sensor packs,projectors, security/surveillance equipment, and air handling. In thecase of lighting, apparatuses and systems can support, carry andreposition a light source, which can include one or more light emittingdiodes (LEDs), a fluorescent lamp, an incandescent lamp, a halide lamp,a halogen lamp, or other type of light source. As such, self-propelledunits can include different mechanisms for supporting different objectsand loads, as well as different mechanisms for traveling on a supportstructure. Furthermore, apparatuses and systems can feature a singleself-propelled unit operating alone, or a group of self-propelled unitsthat operate together as part of a larger integrated system.

The following section describes one example of a self-propelled unitthat supports, carries and repositions many types of objects on asupport structure.

Self-Propelled Unit

FIGS. 1-5 are different views of an example of a self-propelled unit100. Unit 100 is configured to move along two axes of movement in atwo-dimensional support structure. The two axes of movement include afirst axis of movement X, and a second axis of movement Y that isperpendicular to the first axis of movement. Unit 100 includes a carrier120 configured for movable displacement on the support system. A firstconveyor assembly 130 is operable to move carrier 120 on the supportsystem along first axis of movement X. Similarly, a second conveyorassembly 140 is operable to move carrier 120 on the support system alongsecond axis of movement Y. Each of these assemblies includes one or moreconveyors.

Carrier 120 is configured to support, transport and reposition varioustypes of objects or loads on the support structure. As noted above,object 200 can be a powered or non-powered element used in a variety ofapplications, including but not limited to lighting, signage, displays,HVAC, decorations, Wi-Fi, location service, anchors, disabilityservices, audio components, store guidance, immersive entertainmentlighting, UV cleaning, custodial, power distribution, stand-alone sensorpacks, projectors, security/surveillance equipment, and air handling.Referring to the example of FIG. 2, object 200 is a lighting element 202attached to a lower section of carrier 120. Lighting element 202 isschematically shown in dashed lines to indicate that the actual size,shape and orientation can vary depending on the type of light elementand manner of use.

The self-propelled unit 100 also includes power contacts 160 configuredto supply power to circuitry of the unit 100 (see 1010 in FIG. 6), whichin turn provides controlled drive power to first conveyor assembly 130,second conveyor assembly 140 and if required, object 200. Contacts 160are configured as retention lip contacts located in a recess 129 thatextends around the perimeter of carrier 120. As will be explained, powercontacts 160 are configured to engage one or more contacts provided on asupport structure and maintain electrical contact with the contacts onthe support structure as the unit 100 moves between locations on thesupport structure.

Each conveyor assembly can encompass one or more conveyors. In thepresent example, each conveyor assembly encompasses two conveyors onopposite sides of the unit. Referring to FIG. 5, first conveyor assembly130 includes a first conveyor 132 linearly arranged along a firstconveyor path 133 and a second conveyor 134 linearly arranged along asecond conveyor path 135. First conveyor path 133 and second conveyorpath 135 extend parallel to one another and to first axis of movement X.Second conveyor assembly 140 includes a third conveyor 142 linearlyarranged along a third conveyor path 143, and a fourth conveyor 144linearly arranged along a fourth conveyor path 145. Third conveyor path143 and fourth conveyor path 145 extend parallel to one another and tosecond axis of movement Y.

Carriers similar to 120 can have a variety of geometric configurations.In the present example, carrier 120 has a square configuration thatfeatures a first side 122, a second side 124, a third side 126 and afourth side 128. First side 122 and second side 124 intersect at a firstcorner 121, and the second side 124 and third side 126 intersect at asecond corner 123. Third side 126 and fourth side 128 intersect at athird corner 125, and the fourth side 128 and first side 122 intersectat a fourth corner 127. As such, first conveyor 132 partially occupiesfirst corner 121, second conveyor 134 partially occupies third corner125, third conveyor 142 partially occupies second corner 123, and fourthconveyor 144 partially occupies fourth corner 127.

Various types of conveyors can be utilized to allow a carrier such as120 to move along support structures in multiple axes. For example,conveyors can feature various types of gears, wheels, and tracks drivenby motors to move the carrier. In the present example, first conveyor132 includes a first gear assembly 172, second conveyor 134 includes asecond gear assembly 174, third conveyor 142 includes a third gearassembly 176, and fourth conveyor 144 include a fourth gear assembly178. Gear assemblies can feature any number and arrangement of gears. Inthe example, first gear assembly 172 includes two gears 172 a and 172 bextending in parallel to one another. Second gear assembly 174 likewiseincludes two gears 174 a and 174 b. Third gear assembly 176 alsoincludes two gears 176 a and 176 b, and fourth gear assembly 178includes two gears 178 a and 178 b. Each of the gears 172 a, 172 b, 174a, 174 b, 176 a, 176 b, 178 a and 178 b has a plurality of teeth 180that are operable to engage a support structure having a speciallyconfigured surface, such as rack arranged along a tracked grid system.In the case of a rack, each gear works as a pinion on the rack.

Each side of the carrier extends alongside of at least one gear having agear path parallel to first axis of movement X, and at least one gearhaving a gear path parallel to second axis of movement Y. Morespecifically, each side extends alongside of exactly one gear having agear path parallel to one of the first and second axes of movement, andexactly two gears having a gear path parallel to the other of the firstand second axes of movement. Moreover, each side extends alongside ofone of the first conveyor 132 and second conveyor 134, and with one ofthe third conveyor 142 and fourth conveyor 144. In this arrangement eachside coincides with one conveyor that moves carrier 120 along first axisof movement X and one conveyor that moves the carrier along second axisof movement Y.

In the example using linear gear teeth, conveyors configured to producemotion of the carrier in a particular direction have teeth alignedperpendicular to the direction of desired travel along the correspondingpath. Each gear of such a conveyor rotates about an axis offset butotherwise generally perpendicular to the respective gear path. Forexample, the gears 172 a, 172 b have teeth aligned perpendicular to thefirst conveyor path 133 and rotate about respective axes offset butotherwise generally perpendicular to the first conveyor path 133. In theexample, the gears 174 a, 174 b have teeth aligned perpendicular to theconveyor path 135 and rotate about respective axes offset but otherwisegenerally perpendicular to the conveyor path 135. Continuing with theexample, the gears 176 a, 176 b have teeth aligned perpendicular to theconveyor path 143 and rotate about respective axes offset but otherwisegenerally perpendicular to the conveyor path 143; and the gears 178 a,178 b have teeth aligned perpendicular to the conveyor path 145 androtate about respective axes offset but otherwise generallyperpendicular to the conveyor path 145.

The self-propelled unit 100 includes four on-board motors to drive thefour conveyors, the motors being substantially shown in dashed lines inFIG. 5 to indicate their approximate locations inside carrier 120. Themotors include a first motor 182, a second motor 184, a third motor 186and a fourth motor 188. First motor 182 drives first conveyor 132,second motor 184 drives second conveyor 134, third motor 186 drivesthird conveyor 142 and fourth motor 188 drives fourth conveyor 144. Aswill be explained, motors 182, 184, 186 and 188 are operable to drivetheir respective conveyors in a coordinated manner to move unit 100along either the first axis of movement X or second axis of movement Y.

Carriers like the example in FIGS. 1-5 can utilize a variety of motorand conveyor combinations, including but not limited to servo motors andstepper motors that drive gear assemblies. Carriers can also utilizelinear magnetic motors and friction motors. In the case of frictionmotors, the non-driving gears can include a mechanism for lifting thenon-driving gears off of the track. Although the present example isdescribed with four motors, it is possible to use fewer motors or moremotors. In one example, a single motor drive four conveyors, using twotransfer cases and a transmission. In another example, two motors drivefour conveyors, with a first motor driving one pair of conveyors, and asecond motor driving the other pair of conveyors. For example, a carriercould feature a first motor that drives the first gear assembly 130(i.e. drives both the first conveyor 132 and second conveyor 134), and asecond motor that drives the second gear assembly 140 (i.e. drives boththe third conveyor 142 and fourth conveyor 144). Alternatively, eachconveyor can have one or more motors. In the case of a gear assemblyfeaturing multiple gears, for example, each gear can be driven by aseparate motor. As an alternative, carriers can be propelled by linearmotors, such as a linear synchronous motors. Reference characters 182,184, 186 and 188 are each intended to designate any kind of motor thatcan be used to drive gear assemblies in accordance with the presentexample.

During movement of carrier 120 in a given direction, the appropriatemotors are operated to distribute motive power either to first conveyorassembly 130 via first conveyor 132 and second conveyor 134, or tosecond conveyor assembly 140 via third conveyor 142 and fourth conveyor144. First motor 182 and second motor 184 are configured to operate inunison to activate first conveyor assembly 130 and move unitself-propelled 100 on a support structure along first axis of movementX. Similarly, third motor 186 and fourth motor 188 are configured tooperate in unison to activate second conveyor assembly 140 and move unit100 along second axis of movement Y. When first motor 182 and secondmotor 184 are activated, gears 172 a and 172 b rotate on first side 122,and gears 174 a and 174 b rotate on third side 126. During this time,third motor 186 and fourth motor 188 do not operate, such that gears 176a and 176 b on second side 124 and gears 178 a and 178 b on fourth side128 are idle. When third motor 186 and fourth motor 188 are activated,gears 176 a and 176 b rotate on second side 124 and gears 178 a and 178b rotate on fourth side 128. During this time, first motor 182 and thirdmotor 186 do not operate, such that gears 172 a and 172 b on first side122 and gears 174 a and 174 b on third side 126 are idle. Self-propelledunits like unit 100 can move along a support structure in predeterminedincremental movements. Intelligent locomotion of a self-propelled unitcan be controlled by a controller set, as explained in subsequentsections.

Self-propelled units like unit 100 can be used on different types ofsupport structures. Some support structures may include atwo-dimensional grid track featuring a longitudinal slot or gap thatextends through the track, with the self-propelled unit traveling on thetrack above the slot. The slot can allow the unit to connect to a lightelement or other object through the slot, with the light element orother object being carried beneath the track, while the unit rides ontop of the track. The slot for example is continuous and extends throughintersections of the track to allow the light element or other object tobe carried to different location. The continuous slot creates gaps andvoids through the bottom of the track at every intersection. Theself-propelled unit is able to traverse or cross over the gaps and voidswhen traversing intersections. When crossing an intersection, sectionsof the self-propelled unit will temporarily pass over the gap or void,at which time the sections of the self-propelled unit are suspended andno longer supported by the track. One example of this scenario is shownin FIG. 11, which will be described in more detail in a subsequentsection. When sections of the self-propelled unit pass over gaps in thetrack, the suspended sections, however, are adequately supported byother sections of the self-propelled unit to maintain proper engagementbetween the unit and track.

The physical arrangement of gear assemblies 130 and 140, and theirrespective gears, allow self-propelled unit 100 to traverse gaps atintersections in a support structure and still remain supported on thesupport structure. In the scenario shown in FIG. 11, for example, threegears remain in contact with the grid track as the self-propelled unitenters a corner section of the grid track. The relative dimensions,orientations and spacings of gears 172 a, 172 b, 174 a, 174 b, 176 a,176 b, 178 a and 178 b are selected so that appropriate gears remainengaged with the track at all times. At least one gear having a gearpath in the X direction remains in contact with the track, and at leastone gear having a gear path in the Y direction remains in contact withthe track. In the scenario in FIG. 11, two gears having a gear path inthe X direction remain in contact with the track, and one gear having agear path in the Y direction remains in contact with the track. Thisensures that self-propelled unit 100 is able to continue moving ineither the X direction or Y direction upon reaching the corner section.As will be explained, self-propelled unit 100 can also be supported byflanges in the track that slidingly engage recess 129.

Carriers like 120 can have various constructions, including hollowframes or solid walled construction. Solid walled construction can bedesirable to protect the motors and other sensitive components fromcontaminants. In the present example, carrier 120 features a solidwalled housing 190. Solid walled housings can have various shapes,including but not limited to circular or polygonal shapes that partiallyenclose the conveyors. Housing 190 has a generally square shape having afirst sidewall 192, a second sidewall 194, a third sidewall 196 and afourth sidewall 198. Referring back to FIG. 1, first sidewall 192,second sidewall 194, third sidewall 196 and fourth sidewall 198 eachdefine a central aperture 191 that exposes one of the gears insidecarrier 120. In addition, first sidewall 192, second sidewall 194, thirdsidewall 196 and fourth sidewall 198 each jointly define a corneraperture 193 with an adjacent sidewall as shown, which exposes one ofthe gears inside carrier 120. First conveyor assembly 130 and the secondconveyor assembly 140 each project through two central apertures 191 andtwo corner apertures 193 and out of housing 190 in a position forengagement with the support structure.

Housing 190 includes an upper section 195 that houses a circuit board199, and a lower section 197 that houses first conveyor assembly 130 andsecond conveyor assembly 140. Upper section 195 and lower section 197can be integrally formed as a one piece body of unitary construction. Asan alternative, upper section 195 and lower section 197 can bemanufactured as separate parts and joined together to form the housingusing riveting or thermal expansion. Lower section 197 includes aconnector 151 for mounting or otherwise attaching object 200 to carrier120. Connectors can include any type of attachment mechanism suitablefor attaching an object to the lower section, including but not limitedto various types of brackets, mounts, adapters, couplings, receptacles,sockets, clamps, clips, hooks, supports or other attachment mechanisms.In one example, a connector can take the form of a standard signalfemale port. The female port can be connected to an intermediate adapterwith an integrated port for a specific load. The object can be mountedby inserting, plugging or screwing the object into the integrated port.Unit 100 in the present example is configured as a self-propelledlighting unit, and the aforementioned lighting element 202 providesillumination to an area in proximity to the carrier. Moreover, connector151 is a socket or other type of receptacle for mounting lightingelement 202 to carrier 120. Depending on the type of lighting elementused and/or the mode of operation of the lighting element, light can bewidely dispersed around unit 100, or concentrated to a specific areadirectly beneath the unit.

Control System

FIG. 6 illustrates a functional block diagram of a control system 1000for controlling operation of at least one self-propelled unit 1010,which may be a unit like 100 described in the previous sections. System1000 includes one or more units 1010, a communications transceiver 1020,a load 1030, a system controller 1050, a memory 1055 and an input/output(I/O) panel 1040. Operation of system 1000 is managed by systemcontroller 1050. The system controller 1050, along with the memory andpossibly the I/O panel and/or the transceiver, may be configured as adedicated wall unit, or the system controller 1050 and associatedelements may take the form of a more generic computer-like device, e.g.a user terminal computer, a server, a mobile device or the like.Although not shown in detail, such a system controller 1050 may includea central processing unit (CPU), in the form of circuitry forming one ormore processors, for executing program instructions. System controllerhardware typically includes an internal communication bus, programand/or data storage for various programs and data files to be processedand/or communicated by the system controller. The hardware elements,operating systems and programming languages of such a system controllerare conventional in nature, and it is presumed that those skilled in theart are adequately familiar therewith.

System controller 1050 is coupled to memory 1055 and I/O panel 1040.System controller 1050 is configured, upon execution of programinstructions stored in memory 1055, to control the movement andoperation of each unit 1010 in response to an input received from theI/O panel 1040. System controller 1050 may communicate wirelessly withunit 1010 via system controller communications transceiver 1020.Alternatively, system controller 1050 may be coupled via a wiredconnection to system controller communications transceiver 1020.

The I/O panel 1040 is a user interface device that may include atouchscreen display for presentation of a graphical user interface andother information, buttons or switches that are actuated by a user, acomputer pointing device, such as a mouse, touchpad, trackball, or thelike. The I/O panel 1040 may be collocated with system controller 1050or may be located remotely. In addition, the I/O panel 1040 may also becoupled wirelessly via, for example, Bluetooth or Wi-Fi to systemcontroller 1050. Moreover, it is possible for the I/O panel 1040 to becoupled with a hardline wired connection. As explained in more detailbelow with reference to FIGS. 7 and 8, system controller 1050 respondsto inputs from the I/O panel 1040.

Memory 1055, in addition to storing the programming instructions forsystem controller 1050, may also store information (such as operationalinformation and configuration information) about each unit 1010 insystem 1000, information for presentation on the I/O panel 1040, or thelike.

System controller communications transceiver 1020 may be configured toexchange communications between one or more of the units 1010 and thesystem controller 1050. Assuming wireless communication, by way ofexample, the system controller communications transceiver 1020 may beconfigured to communicate according to one or more communicationprotocols, such as Wi-Fi, Zigbee, Z-wave, Bluetooth, X10 or the like. Inanother example, unit 1010 could use a wired link (power line) for datacommunication. Given that the retention lips have contact points forpower source and that there is a power source that feeds to theinfrastructure (support structure), data transmission could occur overthe power line as an alternative to or in conjunction with wirelesscommunication. Other options include comm over power, and inductivepower and Li-Fi.

Unit 1010 includes a communication transceiver 1011, a carriercontroller 1012, sensor(s) 1013, a power supply 1014, power input 1015,load drivers 1016 and motors A-D. While only one unit 1010 is shown indetail, system 1000 may include multiple units that are configuredidentically or differently. For ease of discussion, only unit 1010 willbe described in detail.

Although purpose built logic circuitry can be used, carrier controller1012 is typically implemented by a programmable device such as amicroprocessor or a microcontroller, configured to execute programs andprocess data that controls operation of unit 1010. A microcontroller istypically a ‘system on a chip’ that includes a central processing unit(CPU) and internal storage; therefore, a microcontroller implementationmight incorporate carrier controller 1012, and a memory within themicrocontroller chip.

In the present example, unit 1010 utilizes wireless links to communicatewith system controller 1050. Communications transceiver 1011 is a radiofrequency (RF) wireless transceiver that is coupled to carriercontroller 1012. Assuming a wireless implementation of thecommunications, the communication transceiver 1011 may conform to anyappropriate RF wireless data communication standard such as wirelessEthernet (commonly referred to as Wi-Fi), Z-wave, X10, Bluetooth Zigbeeor the like. At a still relatively high level, communicationstransceiver 1011 may include RF communication circuitry coupled tocarrier controller 1012. The wireless protocol and applicable powerlevels, however, would typically be compatible with those used by systemcontroller communications transceiver 1020, to facilitate wirelesscommunications between the transceivers 1011 and 1020.

Sensors 1013 may include one or more sensors for detecting intersectionsof a support structure in which unit 1010 travels. Sensors may includeinfrared (IR) sensors, global positioning system (GPS) sensors,ultrasonic sensors, video sensors, image sensors, optical sensors,magnetic field sensors, voltage sensors, radio frequency sensors, lightintensity sensors, or the like. The sensors 1013 may be connected tocarrier controller 1012 to facilitate collection, analysis, andcommunication of sensor data and/or data derived from the sensor data.For example, sensors 1013 may provide an indication that unit 1010 hasreached an intersection within the support structure.

Power supply 1014 converts power from power input 1015 to one or moreappropriate forms/levels required by the various electronic componentsof unit 1010 and distributes the converted power to those electroniccomponents. Power input 1015 may receive power from the supportstructure that carries unit 1010, which may be a track system or othertype of support structure as described in previous sections herein. Forexample, power input 1015 may receive electrical power via retention lipcontacts, such as contacts 160 described previously, that are in contactwith electrical contacts within the support structure, such as first andsecond electrical contacts 662 and 664 in track modules 600 (describedlater). In this arrangement, the retention lip contacts receive powersupplied via the support structure. The power may also be supplied viaan induction power supply system within channels of the supportstructure. Alternatively, power may be supplied via conductive lubricantto provide power through the gears.

Unit 1010 may be configured to provide different functions for aparticular space, such as a multi-purpose space. For example, in asystem that deploys multiple units (such as the system that will bedescribed in connection with FIGS. 7 and 8), some of the units in thesystem may be configured with loads 1030 that enable the units tofunction as lighting devices, while other units in the system may beconfigured with loads that enable the units to function as displaydevices, wireless network access points, space environment sensors (e.g.smoke alarms, carbon monoxide alarms or the like) or other devices. Aunit, such as unit 1010, may have one or more loads connected to it, andthe carrier controllers 1012 may be configured to output control signalsaccording to the one or more connected loads 1030.

Carrier controller 1012 also provides control signals to load drivers1016. The respective units 1010 may be configured as lighting devices,display devices, sensor devices, wireless network access points or thelike. Each carrier controller 1012 may be configured to provide drivercontrol signals depending upon the type of load to the load drivers1016. For example, if the connected load is a light source, carriercontroller 1012 may supply driver control signals suitable for drivingthe light source to output light according to a selected configuration.The selected configurations will be described in more detail withreference to FIG. 7.

Carrier controller 1012 is also coupled to a first conveyor assembly1091 that includes motor A and motor B, and to a second conveyorassembly 1092 that includes motor C and motor D. Carrier controller 1012provides drive signals to the respective conveyor assemblies 1091, 1092based on an assigned travel order received from system controller 1050.Motors A-D of the respective first and second conveyor assemblies 1091and 1092 may also provide feedback regarding the number of rotationsand/or other operation information that may be used in distancedtraveled and/or location estimations, as well as feedback regardingblockages, or broken gear teeth. Location services (e.g. GPS, UWB, Etc.)verify that the travel order resulted in the correct location andoutput. Motors A-D may be servo motors, stepper motors or other electricmotors having the appropriate feedback signals.

Operational processes of system 1000 will now be described with specificreference to FIGS. 7 and 8.

FIG. 7 illustrates an example of a control process 1100 for a systemthat utilizes self-propelled units, such as the self-propelled unitsdescribed with reference to the earlier Figures. Control process 1100 isimplemented through the I/O panel, such as I/O panel 1040, which iscoupled to system controller 1050. In step 1105, a user selects a systemconfiguration encompassing a number of self-propelled units via agraphical user interface, such as a touchscreen display, toggleswitches, pushbuttons or the like, coupled the I/O panel 1040. Forexample, in response to the user inputs, the I/O panel 1040 may presentto the user a number of system configuration options at step 1110 fromwhich to choose. The presented system configuration options may bepredefined configurations that were previously set up by the user,preset by the system, or by another user of the system. For example, ifthe system is implemented in a multi-purpose space, each of thepredefined configurations may be set up by the users of the space tohave each of the units in the system at a preset location in the supportstructure depending upon the use of the space. In some instances, thepredefined system configuration may arrange the self-propelled units foruse as a night club, a restaurant, an office space, a school, a retailestablishment or the like. Each of these different uses may have definedpreset locations for the self-propelled units in the system. Memory 1055may store the preset locations of the respective self-propelled units aspart of a predefined configuration corresponding to a particular usageintended from the multi-purpose space. Selections from among existingconfigurations may be responsive to manual input or automatic criteria,such as day and/or time. Some uses may require operation of all of theself-propelled units, while other uses may not. In such instances, thereare number of ways to manage the use or allocation of self-propelledunits. For example, the system can utilize a magazine-style hopperlocated inside a wall, or above a ceiling. Units that are needed for aparticular use are released from the hopper, and units on the track thatare not needed are returned to the hopper. Alternatively, unused unitson the track system can migrate to a remote location on the tracksystem, for example at a side location or far corner above a room, wherethe unused units are parked in a hibernation mode.

The preset locations in the predefined configuration may be determinedbased on the set-up and/or functional capabilities of eachself-propelled unit in the system as selected or most applicable to anintended usage of the space. As described with reference to FIG. 6, eachunit may be constructed or set-up as a lighting device, a sensor, awireless network access point (e.g., Wi-Fi, Bluetooth or the like), adisplay or some other specific arrangement. The predefinedconfigurations are built taking into account these specific unitarrangements. The predefined configurations also include predefinedsettings for each load of a self-propelled unit. For example, when amulti-purpose space is used as a retail store, the settings for therespective load driver, such as load driver 1016, may be different fromthe settings used when the multi-purpose space is utilized as a nightclub. Specifically, the control signals applied to the load driver for alight in the retail store example may be different than the controlsignals applied to the load driver for the same light in the night clubexample. The predefined configuration may also include settings forcontrol signals that are to be applied to the respective load drivers,such as load driver 1016. Alternatively, the carrier controller 1012 maybe configured with a memory that stores the load driver settings foreach predefined configuration. In other examples, the carrier controllersends appropriate control signals over a universal communicationinterface such as usb-c. The load driver then is either built into theload itself or into an intermediate adapter between the connector andthe load.

Once the system configuration is selected at step 1110, the originlocation of each self-propelled unit in the system is determined at step1115. System controller 1050 may directly inquire with eachself-propelled unit in the system via a communications transceiver, suchas communications transceiver 1020, as to the origin location of therespective self-propelled unit in the support structure. The originlocation determination may be made in a variety of ways. For example,each respective self-propelled unit may respond via a communicationtransceiver 1011 with a detector output indicating that unit's locationwithin the support structure, a count of the number of turns of a gearof one of the conveyor assemblies, the rotations of a servo motor of oneof the conveyor assemblies, retrieving it from a memory, or the like.Alternatively or in addition, if a sensor has picked up an identifiablemarking from the track, e.g. a barcode or RF ID at the last intersectionthe self-propelled unit crossed, that information may be sent to thesystem controller 1050 for use in the location determination for theparticular self-propelled unit. Upon determining the origin location ofeach self-propelled unit in the system at step 1115, the process 1100proceeds to step 1120. At step 1120, the target location for each unitin the system is determined based on the predefined configurationselected at step 1110.

Each self-propelled unit in the group of units will have its ownassigned path from the respective self-propelled unit's origin locationto the target location for that particular unit. The system controllermay determine the assigned path using a number of different movementrules. The movement rules dictate the movement of each respectiveself-propelled unit from its respective origin location along thesupport structure (shown in the other examples) to the respective unit'starget location. The movement rules may, for example, establish right ofways for each respective self-propelled unit at intersections in thesupport structure. For example, the northernmost self-propelled unit mayhave the right-of-way when approaching an intersection, followed byeasternmost self-propelled unit, followed by southernmostself-propelled, and lastly, the westernmost unit. Alternatively, theright-of-way may be determined as being clockwise or counter-clockwise.Similar rules may also be established to avoid collisions betweenself-propelled units as the respective units travel to their targetlocations. For example, an algorithm such as last in, first out (LI-FO)may be implemented to avoid collisions. There may also be a rule formaintenance routing the objective of which is to have all of the unitstravel approximately the same distances (over their lifetimes) so as toensure adequate lubrication of the support structure and the gears ofthe respective self-propelled units.

Once the system controller determines the assigned path for eachself-propelled unit of the system, the system controller generates anindividualized travel order for assignment to each respectiveself-propelled unit, and transmits the assigned travel order via thesystem controller communication transceiver, at step 1130, to each ofthe respective self-propelled units. The travel order may contain travelinformation such as directions to the target location, right-of-wayinformation, and other travel information. The travel order mayoptionally include load driving information. When a self-propelled unitreceives its assigned travel order, the unit executes a transition, atstep 1135, from the origin location to the target location. Themovements of the respective self-propelled units are based oninformation contained in the travel orders. Upon completion of theassigned travel order, each respective self-propelled unit verifies itsarrival at the target location by providing an image, a sensor output, agear count a servo count, or the like (1140). For example, an image maybe collected by a camera on the respective self-propelled unit andtransmitted to the system controller or the I/O panel. Alternatively,when the unit completes the assigned travel order, the carriercontroller may transmit via a carrier communication transceiver a servorotation count to the system controller. In addition, a location code ormagnetic strip along the support structure may be used to also indicatethe position of the unit. Radio Frequency-based location services basedon Bluetooth or Global Positioning System (GPS) may also be used todetermine the location of the respective units. As an alternative,locating means can include Ultra Wide Band (UWB) location technology.The respective self-propelled units may transmit their positions to thesystem controller for future reference.

Systems can include distributive processing that allows each carrier toknow the relative position or location of all of the other carriers.This capability can allow a single carrier to think or act on behalf ofthe group, circumventing a central processor.

FIG. 8 is a flowchart of an example process 1200 by which aself-propelled unit is instructed to perform a movement. Process 1200 isperformed by system controller 1020 of FIG. 6 to enable a unit 1010 tomove within a support structure.

At step 1205, system controller 1020 receives an input selecting apredefined configuration. The input may be received from a user via theI/O panel or via another user interface.

In response to the user selection, the system controller executes a“census” operation, at step 1210, to determine the last verifiedlocation of each of the self-propelled units in the system. The censusoperation may be an inquiry operation performed by the system controllerto confirm or verify the location of each self-propelled unit in thesystem. For example, the system controller may access a data structurestored in a memory, such as memory 1055, to retrieve a last known orexpected location of the respective self-propelled units as reported bythe respective units after completion of a travel order. Alternatively,the system controller may transmit an inquiry to each self-propelledunit in the system requesting a response including the respective unit'slocation from each respective unit.

In response to results of the census, the system controller, at step1215, may transmit a request addressed to each self-propelled unitrequesting the latest servo rotation count, sensor output, or otherinformation that enables the system controller to verify that thelocation stored in the data structure is the same location as reportedby the respective self-propelled unit. Any discrepancies between thelocation stored in the data structure and the location reported by theself-propelled unit is resolved based on unit's reported location. Oncethe location of each self-propelled unit is verified at step 1215, thesystem controller may begin calculating at step 1220 the travel orderindicating the route each respective self-propelled unit will beassigned to arrive at the target location to meet the selectedpredefined configuration. The system controller calculates variousparameters for each respective self-propelled unit, such as distance tobe traveled by each respective unit, available pathways for travel froman origin location to a target location, collision avoidance and ease oftravel rules (e.g., right-of-way rules at intersections orlast-in-first-out rules of travel), and maintenance rules.

Maintenance rules are rules that insure that the support structureremains lubricated and that each unit travels approximately the samedistance over the same time period. For example, the self-propelledunits lubricate the support structure as they move through the supportstructure, so if a portion of the support structure has not beentraveled through recently (e.g., within the past week or the like) by aself-propelled unit, the system controller may assign a travel order toa respective self-propelled unit to travel through the particularportion of the support structure to refresh the lubricant in thatportion of the support structure. Another maintenance rule may be forall self-propelled units to travel approximately the same distance overa unit lifespan so that the self-propelled units in the system all incurthe same amount of wear over a given time period. It is beneficial ifthe amount of wear is kept approximately equal on all the self-propelledunits so that any repairs may be performed on all the units at the sametime, instead of on a unit-by-unit basis at different times.

Once system controller 1020 has calculated the pathway distances andaccounted for the collision avoidance and ease of travel and maintenancerules for the respective units in step 1220, the system controllergenerates a travel order for each respective self-propelled unit at1225, and assigns the respective travel orders to the respective unitsfor execution. As part of the assignment at 1225, the system controllersends, for example, via a communications transceiver, the respectivetravel orders in a message addressed to the respective unit to which thetravel order has been assigned.

The respective self-propelled units receive their assigned travelorders, and begin executing the travel orders. At step 1230, therespective processor of each respective self-propelled unit outputsmovement commands to the respective unit servos (i.e., electric motors)according to the assigned travel order. As the self-propelled units moveabout the support structure on their way to their respective targetlocations, each respective self-propelled unit may likely encounter anintersection in the support structure.

Upon encountering a support structure intersection, the respectiveself-propelled unit performs a support structure intersectionverification at step 1235. The support structure intersectionverification is a process performed by the carrier controller of eachrespective unit. The respective carrier controller 1012 obtains anidentifier associated with the support structure intersection andcompares that to an intersection identifier in the assigned travelorder. For example, each self-propelled unit may include sensors, suchas an infrared (IR) detector, a radio frequency identifier (RF)detector, an electrical contact point, a magnetic contact point or thelike, to detect some indicator associated with each intersection thatuniquely identifies each intersection in the support structure to therespective self-propelled unit.

If an IR detector is used, for example, a respective intersection in thesupport structure may have a unique IR reflector or code that uniquelyidentifies the intersection to the unit's processor in controller 1012.In another example, each respective self-propelled unit may have amagnetic sensor, and each respective intersection of the supportstructure may be marked with unique magnetic patterns, magnetic fieldstrengths, or combinations thereof that uniquely identify—the respectiveintersection from other intersections in the support structure. In yetanother example, the self-propelled unit may have an electric contactthat makes physical contact with electrical contacts in the vicinity ofa support structure intersection. In response to making electricalcontact between the unit's electrical contact and the electricalcontacts in the vicinity of the intersection, the carrier controller maydetect a voltage or series of voltages (in the case of multiplecontacts) that uniquely identify the respective intersection.

In a specific example of the support structure intersection verificationprocess at step 1235, the carrier controller determines the number ofrotations of a servo motor made until the self-propelled unit reached anintersection. Upon detecting an intersection by the respective unit'ssensor or detector, the carrier controller compares the intersectionidentifier obtained by the carrier sensor or detector to theintersection identifier provided in the travel order. If theintersection is correct, the carrier controller may compare the numberof rotations that the servo motor actually traveled to reach theintersection to the number of rotations in the travel order that therespective self-propelled unit was supposed to travel until reaching theintersection. Note that the number of rotations may also refer tofractional parts of a rotation. At step 1240, the carrier controllerdetermines if there was an error in the number of rotations. If thedetermination is YES, there was an error, for example, in the number ofservo rotations, the process 100 proceeds to step 1245. At step 1245,the carrier controller recalibrates the servo count in the assignedtravel order to match the actual number of servo rotations. Similarly,if the wrong intersection is found, the carrier controller may updatethe travel order. These errors may be logged in a failure data structurefor later transmission to the system controller by each respectivecarrier controller. The system controller analyzes the errors logged inthe failure data structure and uses the results of the analysis as partof a learning algorithm that adjusts calculation parameters or the likethat are used in step 1220. For example, if the number of errorsoccurring at a particular intersection in the support structure exceedsa maximum threshold, the system controller may indicate, for example, onthe I/O panel that maintenance at the particular intersection locationis required or the like.

However, if at step 1240, NO errors are found, process 1200 proceeds tostep 1250. At step 1250, the respective self-propelled unit arrives atthe target location, and the carrier controller of each respective unitnotifies the system controller that the respective unit has arrived atthe target location in the assigned travel order. In addition, eachrespective self-propelled unit may notify the system controller of thenumber of servo rotations performed and/or identifications ofintersections crossed to arrive at the target location. After verifyingthe servo rotations and/or intersection identifications with the systemcontroller at step 1255, process 1200 proceeds to step 1260.

The carrier controller saves the target location for use as the originlocation when a next movement is needed. The carrier controller alsotransmits the target location to the system controller for futureverification or census taking.

System 1000 may also incorporate diagnostics modes. For example, if aparticular unit has repeated errors at a specific intersection, adifferent unit may be instructed to traverse the intersection to see ifthe error is repeated. This may be used to diagnose whether the problemis with the particular unit or the particular intersection.

As noted above, self-propelled units can be configured to support,transport and reposition various types of objects or loads on a supportstructure. Support structures can be configured in various arrangements,and with various types of support elements. The following sectiondescribes a support structure, on which a self-propelled unit such asself-propelled unit 100 or 1010 can support, carry and repositiondifferent types of objects.

Support Structure

FIG. 9 shows a support structure in accordance in the form of a modulartrack system 500. Track system 500 is made up of several track sectionsor “track modules” 600 connected end-to-end in a square shaped grid 502.Grid 502 is made up of six evenly-spaced rows 504 and six evenly-spacedcolumns 506. In this arrangement, track system 500 provides two axes ofintelligent locomotion for a self-propelled unit on the track system. Inparticular, track system 500 provides for movement of one or moreself-propelled units and objects supported on such units along a firstaxis of movement X, parallel to the direction of each row 504, and formovement of one or more self-propelled units along a second axis ofmovement Y, parallel to the direction of each column 506.

Referring to FIG. 10, two track modules 600 of track system 500 areshown in more detail. Each track module 600 has an elongated body 601that defines a longitudinal axis “L”. Each elongated body 601 has afirst end 604 and a second end 606 having a configuration that isidentical to the configuration of the first end. Track modules can beconfigured to join together end-to-end with a miter joint. For example,track modules can have at least one beveled edge on each end that allowsthat end to join with a mating end of another track module in a miterjoint. In the example with one bevel on each end of each module, the onebeveled edge on one module joins with an opposing beveled edge on acomplementary end of another track module. In the example with twobevels on each end of each module, one beveled edge on one module joinswith an opposing beveled edge on an identically-configured end ofanother track module. In the present example, end 602 has a firstbeveled edge 602 a and a second beveled edge 602 b, and end 604 has afirst beveled edge 604 a and a second beveled edge 604 b. First bevelededge 602 a and second beveled edge 602 b are arranged symmetricallyrelative to longitudinal axis L. Likewise, first beveled edge 604 a andsecond beveled edge 604 b are arranged symmetrically relative tolongitudinal axis L.

Beveled edge 602 a of track module 600 on the left side of the Figure isjoined to beveled edge 602 b of track module 600 on the right side ofthe Figure. Each beveled edge 602 a, 602 b, 604 a and 604 b on trackmodule 600 is oriented at an angle α of 45 degrees relative tolongitudinal axis L of the track module. In this arrangement, trackmodules 600 are joined end-to-end in a miter joint, in which the twotrack modules are connected at 90 degrees.

It will be appreciated that track modules need not have symmetricalbeveled edges in order to facilitate end-to-end connections. Inaddition, it will be appreciated that different types of beveledarrangements can be used to accomplish end-to-end miter connections, andthat the symmetrical beveled edges shown thus far are not the onlyconfigurations that will facilitate miter connections. For example, FIG.18 shows two track modules 600′ in accordance with another example,where each track module has a single beveled edge 602′ on each end. Thesingle beveled edge 602′ allows multiple track modules 600′ to be joinedend-to-end in a miter connection. This design allows multiple trackmodules to be assembled into a regular or irregular arrangement, similarto track module 600. However, the single beveled edge 602′ is onlycapable of joining to one other track module 600′ at a time, whichlimits its usage to simpler track geometries.

Support elements can include various means for conveying self-propelledunits on the support structure, including various track configurations.Track configurations can be configured to cooperate with conveyorassemblies of self-propelled units, including but not limited to gearassemblies. Referring to the example in FIG. 10, each track module 600has a track surface 610 that extends longitudinally along elongated body601. Track surface 610 includes a plurality of raised protuberances 612that are arranged in rows that are parallel to longitudinal axis L, andarranged in columns that are perpendicular to longitudinal axis L. Eachprotuberance 612 is in the form of a tooth or projection 614 that isconfigured to mesh with one or more gears of a self-propelled unit, suchas the gears on unit 100. FIGS. 11 and 12 show unit 100 as it wouldappear when being operated on track modules 600.

FIGS. 13 and 14 schematically illustrate how orthogonally arrangedgears, such as gear 172 a and gear 174 a on unit 100, cooperate withprojections 614 on track surface 610. Track surface 610 is configured tocooperate with each gear assembly on unit 100, regardless of thedirection of the gear path. Each gear cooperates with track surface 610in an “active mode”, in which the gear rolls along the track surface,and in a “passive mode”, in which the gear remains idle. When unit 100moves in a direction parallel to a gear's gear path, the gear is in its“active mode”, in which the gear is driven by its motor, and the teeth180 of the gear interdigitate with projections 614. This allows the gearwhen driven by the associated motor to propel unit 100 along the trackin the direction of its gear path. When self-propelled unit 100 moves ina direction perpendicular to the gear's gear path, the gear is switchedto a passive mode. In the passive mode, no power is delivered to thegear, and the gear remains idle. The teeth 180 of the gear pass betweenprojections 614, as shown in FIG. 14, which allows unit 100 to moveperpendicularly to the gear's gear path without interference from thatgear.

Each projection 614 has a projection axis P that extends normal to tracksurface 610. Moreover, each projection 614 is symmetrical with respectto axis P. Projections 614 are spaced uniformly along first axis ofmovement X and along second axis of movement Y. That is, each projection614 is separated from an adjacent projection 614 along first axis ofmovement X by a spacing S, and separated from an adjacent projection 614along second axis of movement Y by the same spacing S, so that thespacing between projections is constant in both directions. This allowstwo track surfaces 610 to be joined in a miter connection at a 90 degreeintersection while maintaining a uniform pattern of projections withoutany discontinuity or interruption in the pattern. The uniform pattern ofprojections between adjacent track sections at intersections allowsgears to travel biaxially on the track in a seamless manner from onetrack module to another track module.

Spacing S is slightly wider than a maximum width W of each gear tooth180 on unit 100. This creates clearance that allows gear teeth 180 oneach gear to interdigitate with projections 614 when the gear is inactive mode, and to pass between projections 614 when that gear is inpassive mode.

Projections can have various geometric shapes and profiles that permittwo-dimensional engagement with gear wheels, including but not limitedto frustoconical shapes, such as conical frustums and square frustums.In the present example, track surface 610 is in the form of a “pyramidrack”. The term “pyramid rack” as used herein means that the projections614 on the track surface are in the form of square frustums, eachfrustum having four trapezoidal shaped sides 616 that extend from a widesquare base 618 and converge toward a smaller flat top face 620. Incontrast, each tooth 180 on the gear has rounded sides 181 that convergefrom a wider base toward a flat end face 183. The tapered roundedconfiguration of each tooth 180 allows the tooth to pass smoothlybetween projections 614 when the gear is in passive mode. As teeth 180pass between projections 614 in the passive mode, the projections act asguides for the teeth.

Depending on how the self-propelled units and track modules areconfigured, track modules can convey self-propelled units in a number ofarrangements. For example, the self-propelled unit can be conveyed ontop of a track module, beneath a track module, or inside a track module.Referring to FIGS. 11 and 12, elongated body 601 of track module 600 isa hollow conduit 630 that allows one or more self-propelled units totravel inside track system 500. Conduit 630 has a first side wall 632defining a first side 634 and a second side wall 636 defining a secondside 638. Conduit 630 also has a top wall 642 that extends between firstside wall 632 and second side wall 636.

Self-propelled units and track modules can be installed in newinstallations in ceiling structures. For example, self-propelled unitsand track modules can be installed above ceiling tiles that are mountedto ceilings at their center portions, leaving spaces between the tileswhere the objects carried by the self-propelled units can travel. As analternative, self-propelled units and track modules can be retrofit toexisting ceilings or overhead structures. For example, track modules canbe mounted to existing ceiling structures with brackets or otherhardware attached to the top of the track module. Top wall 642 has amount in the form of a bracket 644 that allows the top wall to bemounted to a T-bar, frame or other overhead support.

Conduit 630 also has a bottom wall 652 opposite top wall 642. Bottomwall 652 defines an inner surface 654 along which track surface 610extends. Bottom wall 652 defines a large longitudinal slot 656 thatextends along the entire length of track module 600. Slot 656 dividesbottom wall 652 into two sections, including a first wall section 653and a second wall section 655. In this arrangement, track surface 610 isalso divided into two track sections, namely a first track surface 613on first wall section 653 and a second track surface 615 on second wallsection 655. Slot 656 extends between first track surface 613 and secondtrack surface 615, forming a longitudinal passage 657 adapted to permita portion of a movable object, such as light element, to move in andlong the slot as unit 100 travels along track system 500.

Track modules can be connected to a power source and provide electricityto self-propelled units that travel along the track system. Referring toFIGS. 15-17, for example, each track module 600 includes a firstelectrical contact 662 that extends longitudinally along first sidewall632 and a second electrical contact 664 that extends longitudinallyalong second sidewall 636. First electrical contact 662 and secondelectrical contact 664 are in the form of flanges 665 that are connectedto a power supply through the track system. Each flange 665 extendsinwardly into the interior of conduit 630. In these positions, flanges665 align with recess 129 of unit 100. Flanges 665 enter into recess 129as unit 100 enters track module 600, at which time the first electricalcontact 662 and second electrical contact 664 come in contact withcontacts 160 inside unit 100. Flanges 665 slidingly engage recess 129and support self-propelled unit 100 so that the unit is verticallysupported at all times, particularly when a section of the unit issuspended over a slot or gap in the track system. When a section ofself-propelled unit 100 is positioned over a gap at an intersection,such as in the scenario shown in FIG. 11, flanges 665 are positioned inrecess 129 and vertically support the unit so that it maintains properalignment in and engagement with the track system.

Track systems can be arranged in a number of different gridconfigurations. For example, grids can be made up of a plurality ofinterconnected square sections, a plurality of interconnectedrectangular sections, a combination of square and rectangular sections,or other geometric arrangements. The length of each side of a square, arectangle or other shape can depend on numerous factors. Therefore, itcan be advantageous to manufacture track modules with different unitlengths, with longer modules being intended for longer sections oftrack, and shorter modules intended for shorter sections of track. Tracksystems can be manufactured as kits or assemblies containing one or moredifferent types of track module, each module type having a specific unitlength. For example, a first type of track module in the kit can have aunit length of two feet to build a shorter section of track, and asecond type of track module in the kit can have a unit length of fourfeet to build a longer section of track. It will be understood thatthese unit lengths are just examples, and that other unit lengths canutilized depending on the desired configuration.

It can also be advantageous to manufacture individual track pieces or“track segments” to form track surfaces on or in each track module. Forexample, track surface 610 in the present example is formed using aseries of individual track segments that extend inside track module 600.These track segments provide an economic way to manufacture trackmodules of different unit lengths, while reducing the number of trackpart geometries that must be machined so as to accommodate differenttrack module dimensions. Referring to FIG. 19, only two track segmentsare utilized to make track surface 610. The track segments include afirst track segment 611 and a second track segment 613. Track segments611 and 613 have mirror symmetry with respect to one another. Firsttrack segment 611 includes a long side 611 a, a short side 611 b, abeveled end 611 c and a butt end 611 d. Second track segment 613includes a long side 613 a, a short side 613 b, a beveled end 613 c anda butt end 613 d.

Each end of first track segment 611 is configured to be joined toanother first track segment 611, or to a second track segment 613,depending on the arrangement. Likewise, each end of second track segment613 is configured to be joined to another second track segment 613 or toa first track segment 611, depending again on the arrangement. Forexample, beveled end 611 c of first track segment 611 can be joined to abeveled end 611 c of another first track segment 611 to form a linearconnection. Alternatively, beveled end 611 c can be joined to a beveledend 613 c of a second track segment 611 in a miter joint to form a 90degree intersection. Similarly, beveled end 613 c of second tracksegment 613 can be joined to a beveled end 613 c of another second tracksegment 613 to form a linear connection. In addition, beveled end 613 ccan be joined to a beveled end 611 c of a first track segment 611 in amiter joint to form a 90 degree intersection. Butt end 611 d of firsttrack segment 611 can be joined in a butt joint with either a butt end611 d of another first track segment 611, or with a butt end 613 d of asecond track segment 613, which in either case forms a linearconnection.

Projections 614 are uniformly spaced from one another on theirrespective track segments in both the X and Y directions. In addition,projections 614 are spaced uniformly from the sides and ends of theirrespective track segments. Therefore, the pattern and arrangement ofprojections 614 remains uniform and continuous between adjoined tracksegments, without interruption. As track surface 610 proceeds from onetrack segment to the next, the pattern of projections 614 remainsuniform and consistent so that self-propelled units, like unit 100, cantravel smoothly over adjoined track segments. The gear teeth 180 on eachgear can transition smoothly between projections 614 on adjoining tracksegments so that gears in the active mode do not slip or disengage fromtrack surface 610.

First and second track segments 611 and 613 can be joined end to end ina linear arrangement to create a track surface within a track module.Track segments 611 and 613 associated with separate track modules canalso be joined end to end to seamlessly join the two track modulestogether, either in linear path or at a 90 degree intersection.Moreover, track segments 611 and 613 can be connected in differentcombinations and arrangements to accommodate different track modulelengths. Referring to FIGS. 20 and 21, two examples of track surfaces610 are shown as they would be arranged on the inside of a track module600. For clarity, the track surfaces 610 are shown without the rest ofthe surrounding track module 600. In FIG. 20, a first track segment 611is joined end to end with a second track segment 613 in a butt joint oneach side of track surface 610. Each of track segments 611 and 613 istwo feet long, so that track surface 610 is four feet long, toaccommodate a track module length of four feet. In FIG. 21, the sametype of first track segment 611 and the same type of second tracksegment 613 are used, albeit in greater numbers, to construct adifferent track surface 610′. The track section at the top of the Figureis constructed with one first track segment 611 and three second tracksegments 613. The track section at the bottom of the Figure isconstructed with one second track segment 613 and three first tracksegments 611. Each of first and second track segments 611 and 613 is twofeet long, as noted above, so that track surface 610′ is eight feetlong, to accommodate a track module length of eight feet. As theseexamples show, first and second track segments 611 and 613 can be joinedby butt joints or miter joints in various combinations and arrangementsto construct track modules of different lengths. Therefore, tracksegments 611 and 613 can be used to construct track modules of manydifferent sizes, which offers great flexibility in a cost-effective partdesign that minimizes the number of track segments required.

Unless otherwise stated, any and all measurements, values, ratings,positions, magnitudes, sizes, and other specifications that are setforth in this specification, including in the claims that follow, areapproximate, not exact. They are intended to have a reasonable rangethat is consistent with the functions to which they relate and with whatis customary in the art to which they pertain. It is intended by thefollowing claims to claim any and all modifications and variations thatfall within the true scope of the present concepts.

What is claimed is:
 1. A track module comprising: an elongated bodydefining a longitudinal axis and comprising two ends, each endcomprising at least one beveled edge, and at least one track surfaceextending longitudinally along the elongated body, the track moduleconfigured for connection with another track module to construct a tracksystem that provides two axes of intelligent locomotion for a movableobject on the track system, the track module comprising at least oneelectrical contact for supplying energy to the movable object on thetrack system.
 2. The track module of claim 1, wherein the at least onebeveled edge is oriented at an angle of 45 degrees relative to thelongitudinal axis for joining the track module to another identicallyconfigured track module end-to-end in a miter joint.
 3. The track moduleof claim 1, wherein the at least one beveled edge of each end comprisesa first beveled edge and a second beveled edge that are symmetricalrelative to the longitudinal axis.
 4. The track module of claim 3,wherein the first beveled edge and the second beveled edge are eachoriented at an angle of 45 degrees relative to the longitudinal axis,for joining the track module to at least one other identicallyconfigured track module end-to-end in a miter joint.
 5. The track moduleof claim 1, wherein the at least one track surface comprises a firsttrack surface extending longitudinally along a first side of theelongated body, and a second track surface extending longitudinallyalong a second side of the elongated body.
 6. The track module of claim5, wherein the elongated body defines a longitudinal slot that extendsbetween the first track surface and the second track surface, thelongitudinal passage adapted to permit a portion of the movable objectto move in the slot as the movable object travels on the track system.7. The track module of claim 1, wherein the at least one electricalcontact comprises a flange.
 8. The track module of claim 1, wherein thetrack module is configured for connection with another track module toconstruct a track system that provides two perpendicular axes ofintelligent locomotion.
 9. The track module of claim 1, wherein theelongated body of the track module is a hollow conduit.
 10. A tracksystem comprising: a plurality of track modules connected end-to-end,each track module comprising: an elongated body defining a longitudinalaxis and comprising two ends, each end comprising at least one bevelededge, and at least one track surface extending longitudinally along theelongated body, the track system providing two axes of intelligentlocomotion for a movable object on the track system, each track modulecomprising at least one electrical contact for supplying energy to themovable object on the track system.
 11. The track system of claim 10,wherein the at least one beveled edge on an end of each track module isoriented at an angle of 45 degrees relative to the longitudinal axis ofsaid track module, for joining said track module to another track moduleof the plurality of track modules end-to-end in a miter joint.
 12. Thetrack system of claim 10, wherein the at least one beveled edge of eachend comprises a first beveled edge and a second beveled edge that aresymmetrical relative to the longitudinal axis.
 13. The track system ofclaim 12, wherein the first beveled edge and the second beveled edge areeach oriented at an angle of 45 degrees relative to the longitudinalaxis for joining the track module to at least one other track moduleend-to-end in a miter joint.
 14. The track system of claim 10, whereinthe at least one track surface of each track module comprises a firsttrack surface extending longitudinally along a first side of theelongated body of said track module, and a second track surfaceextending longitudinally along a second side of the elongated body ofsaid track module.
 15. The track system of claim 14, wherein theelongated body of each track module defines a longitudinal slot thatextends between the first track surface and the second track surface,the longitudinal slot adapted to permit a portion of the movable objectto move in the slot as the movable object travels on the track system.16. The track system of claim 10, wherein the at least one electricalcontact of each track module comprises a flange.
 17. The track system ofclaim 10, wherein the track system provides two perpendicular axes ofintelligent locomotion.
 18. The track system of claim 10, wherein theplurality of track modules are connected in a rectangular gridcomprising four corners, each corner being formed by two of theplurality of track modules connected end-to-end in a miter joint. 19.The track system of claim 18, wherein each corner defines a windowaperture that provides access into an interior space inside the tracksystem.
 20. The track system of claim 10, wherein the elongated body ofeach track module is a hollow conduit.